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    This document discusses different failure analysis methods including Failure Modes and Effects Analysis (FMEA) and Fault Tree Analysis (FTA). It provides details on how to perform each analysis including defining failures, rating severity, occurrence and detection, and constructing fault trees using logic gates.

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    FailureAnalysis PDF

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    74 views26 pages
    This document discusses different failure analysis methods including Failure Modes and Effects Analysis (FMEA) and Fault Tree Analysis (FTA). It provides details on how to perform each analysis including defining failures, rating severity, occurrence and detection, and constructing fault trees using logic gates.

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    This document discusses different failure analysis methods including Failure Modes and Effects Analysis (FMEA) and Fault Tree Analysis (FTA). It provides details on how to perform each analysis including defining failures, rating severity, occurrence and detection, and constructing fault trees using logic gates.

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    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
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    74 views26 pages

    FailureAnalysis PDF

    Uploaded by

    elektron2010
    This document discusses different failure analysis methods including Failure Modes and Effects Analysis (FMEA) and Fault Tree Analysis (FTA). It provides details on how to perform each analysis including defining failures, rating severity, occurrence and detection, and constructing fault trees using logic gates.

    Copyright:

    © All Rights Reserved
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    Download as pdf or txt
    of 26

    Failure Analysis Methods

    What, Why and How


    MEEG 466 Special Topics in Design
    J im Glancey
    Spring, 2006
    Failure Analysis Methods
    Every product or process has modes of
    failure.
    An analysis of potential failures helps
    designers focus on and understand the
    impact of potential process or product
    risks and failures.
    Several systematic methodologies have
    been develop to quantify the effects and
    impacts of failures.
    Failure Analysis Methods . . .
    Why perform failure analysis?
    Product Development:
    Prevent product malfunctions.
    Insure product life.
    Prevent safety hazards while using the product.
    Process Development:
    Insure product quality
    Achieve process reliability
    Prevent customer dissatisfaction
    Prevent safety or environmental hazards
    Common Failure Analysis
    Techniques
    Cause-Consequence Analysis
    Checklist
    Event Tree Analysis
    Failure Modes & Effects
    Analysis (FMEA)
    Failure Modes, Effects and
    Criticality Analysis (FMECA)
    Fault Tree Analysis (FTA)
    Hazard & Operability Analysis
    (HAZOP)
    Human Reliability
    Preliminary Hazard Analysis
    (PHA)
    Relative Ranking
    Safety Review
    What-If / Checklist Analysis
    What-If Analysis
    For the purpose of this class, two common but
    fundamentally different techniques will be presented in
    detail:
    1. Failure Modes Effects Analysis (FMEA)
    2. Fault Tree Analysis
    Part 1: Failure Modes Effect
    Analysis
    Failure Modes & Effects Analysis
    (FMEA)
    Tabulation of equipment/components and their associated
    single point failure modes, consequences and safeguards.
    Identification/assessment of risk is derived from looking at
    each component (or machine in the case of multi-unit
    manufacturing).
    This is commonly referred to as a bottom-up approach.
    Failure
    Item Identification Description Modes Effects Safeguards Actions
    1
    Car Tire
    -Supports Weight
    -Traction
    -Cornering
    -Smooth Ride
    Flat -Stranded
    -Loose Control
    Spare Tire
    In Trunk
    Acceptable
    as is
    Gas Tank Holds fuel
    2
    Simple Example: Car
    -Empty
    -Blows up
    -Stall
    -Car Destroyed
    -Fuel Gage
    -Locate away
    from Engine
    Acceptable
    as is
    Implementing FMEA
    An FMEA can be implemented using a
    hardware or functional approach, and
    often due to system complexity, be
    performed as a combination of the two
    methods.
    Hardware = loss of a component
    Functional = loss of a function or feature
    Failures
    Need to understand failures which can be
    any of the following:
    Failure is any loss that interrupts the continuity of production.
    Failure is a loss of asset availability.
    Failure is the unavailability of equipment.
    Failure is a deviation from the status quo.
    Failure is not meeting target expectations.
    Failure is any secondary defect
    Failures . . .
    Failures can be:
    pump not working
    seized valve
    broken wire
    software crash
    system down
    reactor melt down
    no money in a checking account
    (inevitable for college student)
    Failures . . .
    Defining the possible (and relevant)
    failures is the key for the analysis to
    produce meaningful results.
    For instance, if all we care about are
    failures that cause injuries or death, then
    the analysis would be much different than
    one that was interested in economical
    problems.
    FMEA Procedure
    Review and understand product or process design; breakdown into components
    (product) or steps (process).
    Brainstorm modes of failure.
    Rate the severity of each effect of failure.
    Rate the likelihood of occurrence for each failure.
    Rate the likelihood of detection for each cause of failure (i.e. the likelihood of
    detecting the problem before it reaches the customer or operator).
    Compute the Risk Priority Number, RPN = Severity x Occurrence x Detection
    Implement corrective actions to minimize the occurrence of the more significant
    failure modes (i.e. the highest RPNs).
    Re-assess the product or process by another cycle of FMEA after the actions
    have been completed.
    Perform regular (re)assessments of failures as needed.
    FMEA Table
    Example: Hydraulic Hose Failure
    Severity, Occurance and Detection ratings are based on a 1 = low to
    10 = high scale.
    The FMEA results clearly show the greatest risk is associated with over-
    pressure failure, and the lowest risk is due to weathering-related failure.
    The excel template shown is above is available at:
    http://research.me.udel.edu/~jglancey/FMEA_Template.xls
    Part 2: Fault Tree Analysis
    Fault Tree Analysis (FTA)
    Graphical model that displays the various
    combinations of equipment failures and
    human errors that can result in the main
    system failure of interest.
    Identification/assessment of risk is derived
    by first identifying faults/hazards.
    A top down approach.
    Definitions
    FAULT
    An abnormal undesirable state of a system or a system
    element* induced 1) by presence of an improper
    command or absence of a proper one, or 2) by a
    failure (see below). All failures cause faults; not all
    faults are caused by failures. A system which has
    been shut down by safety features has not faulted.
    FAILURE
    Loss, by a system or system element*, of functional
    integrity to perform as intended, e.g., relay contacts
    corrode and will not pass rated current closed, or the
    relay coil has burned out and will not close the
    contacts when commanded the relay has failed; a
    pressure vessel bursts the vessel fails.
    Fault Tree Example
    Fault Tree Construction
    Each node in the tree can be represented by a
    combination of events that cause the
    occurrence of the event, by means of logic
    gates
    Each gate has inputs and outputs
    An input can be a basic event or an output of
    another gate
    The development of a fault tree model relies
    on the
    analyst
    analyst

    s understanding
    s understanding of the system
    being analyzed
    It is
    very important
    very important to understand the system
    first in order to build a unbiased fault tree
    Logic (Boolean) Gates
    FTA Structure
    Identifying TOP Events
    Explore historical records (own and others).
    Look to energy sources.
    Identify potential mission failure contributors.
    Development what-ifscenarios.
    Use shopping lists.
    FTA Example
    Consider lamp failing to illuminate when the fluid level is too low.
    Fault Tree Constraints and
    Shortcomings
    Undesirable events must be foreseen and are only analyzed
    singly.
    All significant contributors to fault/failure must be anticipated.
    Each fault/failure initiator must be constrained to two conditional
    modes when modeled in the tree.
    Initiators at a given analysis level beneath a common gate must
    be independent of each other.
    Events/conditions at any analysis level must be true, immediate
    contributors to next-level events/conditions.
    Each Initiators failure rate must be a predictable
    FTA vs. FMEA

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